Collapsible Container For Air Shipment Cargo and Method of Use

ABSTRACT

A collapsible container for air shipment cargo comprises a base, a top and collapsible side walls integral with each other to form a ring. Front and rear walls are hingedly secured to the base. Each of the side walls has upper and lower wall panels hinged together so as to enable each side wall to collapse inwardly. A door may be hinged to one of the side walls. Flaps having fasteners are hinged to the side walls and used to assemble and erect the container. Portions of the top have fasteners which are used to secure the front and rear walls to the top. One of the front and rear walls has upper and lower portions forming an obtuse angle with each other when the container is erected.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 11/227,738 filed Sep. 15, 2005 entitled “Collapsible Container For Air Shipment Cargo and Method of Use”, which is fully incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates to a collapsible container for use in an aircraft cargo hold.

DESCRIPTION OF THE PRIOR ART

Special containers are used on aircrafts for storing fragile parcels containing breakable or perishable goods, or for storing passenger luggage. Due to the limited space available in aircraft cargo holds, the shape of such a container is generally designed to fit the shape of the walls of the aircraft cargo hold or luggage compartment. One of the most important factors airlines use in selecting a suitable container for use in an aircraft cargo hold is gross weight. The heavier the container, the heavier the airplane and the more fuel must be used to fly a predetermined distance.

In order to reduce the space occupied by such a container once it has been emptied, such a container has been designed to collapse. For example, U.S. Pat. No. 5,890,612 discloses a collapsible aircraft container which has a rigid base frame supporting an accordion folding frame. The collapsible container has sides made of canvas and sheet metal plates. The frames are made of steel. Therefore, the container is heavy, even when empty.

Another collapsible aircraft container is disclosed in U.S. Pat. No. 5,941,405. This collapsible aircraft container has a base, support posts and roof made of aluminum and flexible side walls formed from light weight fabric. Again, due to the support posts, the container is heavy, even when empty.

In each of these collapsible aircraft containers, the less the weight the better, as long as the container is sturdy enough to handle normal wear and tear of such use. Consequently, there is a need for a light weight, collapsible airline container which does not include a frame or support posts, thereby reducing its weight.

SUMMARY OF THE INVENTION

The collapsible container of the present invention comprises a base, a top, front and rear wall panels hingedly secured to the base and side walls hingedly secured to the base and top. Each of the side walls comprises upper and lower wall panels hinged together so as to enable each side wall to collapse inwardly. A hinged door is formed in one of the side walls for access to the interior of the erected container.

Once the container is erected, a person may load product(s) or luggage into the interior of the container for shipping purposes. Likewise, prior to collapsing the container, product(s) or luggage may be removed from the interior of the container out the opening or openings formed in one or both of the side walls of the container which may be closed doors or other similar structure.

Although the collapsible container of the present invention is intended for use inside airplane cargo holds or luggage compartments, it may used in any desired environment and is not intended to be limited in its use.

In one embodiment of the present invention, the top of the collapsible airline container is one piece or panel of material having two opposed flanges which may be bent downwardly perpendicular to the generally planar main portion of the top. Fasteners are secured to these flanges in any suitable manner and in one embodiment comprise rotatable latches adapted to pass through openings in the front and rear wall panels or walls of the container during assembly of the container. Of course, any other suitable fasteners may be used to secure the top to the collapsible front and rear wall panels of the assembly during assembly.

The front wall panel of the container in one embodiment comprises one generally rectangular piece or panel of plastic material. However, the front wall panel or front wall may be made of multiple pieces secured together of any suitable material.

The rear wall panel in one embodiment comprises one generally rectangular piece or panel of plastic material. The rear wall panel has a living hinge extending from one side edge to the other side edge which separates the rear wall panel into a generally planar upper portion or section and a generally planar lower portion or section and enables the rear wall panel to be folded into a collapsed position when the container is collapsed. These upper and lower portions or sections of the rear wall panel form an obtuse angle with each other when the container is assembled and lay on top of one another when the container is collapsed. If desired, the rear wall may be made of multiple pieces secured together of any suitable material.

The collapsible airline container further comprises plastic flaps hingedly secured to the side walls. These flaps are secured to the front and rear wall panels of the container during assembly of the container. In one embodiment, three flaps are hingedly secured to one edge of each side wall for securing the side wall to the rear wall panel and two flaps are hingedly secured to an opposing edge of the side wall for securing the side wall to the front wall panel. At least one fastener is secured to each of the flaps. In one embodiment these fasteners comprise rotatable latches adapted to pass through openings in the front and rear wall panels. Of course, any other suitable fasteners may be used to secure the flaps to the collapsible front and rear wall panels.

Each of the wall panels and flaps is preferably made of plastic but may be made of any suitable material. In one embodiment of the present invention, each of the wall panel is made of a plastic material sold under the mark CON-PEARL® by Friedola Gebr. Holzapfel Gmbh & Co. of Germany. The panel material may be selected as appropriate to protect or prevent surface damage to the products being stored and/or shipped in the erected container.

The method of assembling the collapsible airline container comprises multiple steps. Although the method is described with respect to one preferred embodiment, the method may be used with any of the embodiments contemplated by this invention.

In one instance, a collapsed container as described above is first provided. Two operators first lift a top of the collapsed container, thereby erecting side walls of the collapsed container including a collapsed door. The operators then lift, pivot or raise the front and rear wall panels of the collapsed container by pulling on straps secured to these panels of the collapsed container.

One of the assemblers then enters the interior of the container via the open door of the partially erected container. The first assembler located outside the partially erected container passes rotatable latches located on the flanges of the top of the container through openings in the front and rear wall panels of the container. The assembler located inside the container then rotates the latches to prevent the latches from passing back through the openings in the front and rear wall panels of the container. The second assembler located outside the container also passes the fasteners in the form of rotatable latches located on the flaps of the container through openings in the front and rear wall panels of the container. The assembler located inside the container then rotates the latches to prevent the latches from passing back through the openings in the front and rear wall panels of the container and secure the flaps to the front and rear wall panels of the container.

After the interior of the erected container is loaded with product, one of the assemblers may close and lock the door of the container in a closed position.

In this manner, the container may be quickly and inexpensively assembled or erected. For purposes of this document, the term “fastener” refers to any type of fastener including a rotatable latch.

In order to disassemble the container, a person enters the interior of the erected container and rotates the rotatable latches to open them so that the flaps may be separated from the front and rear wall panels and the top may be separated from front and rear wall panels by a second operator located outside the container. After the person previously inside the interior of the container exits the container via the opening where the door is located, the other person pulls the flaps away from the front and rear wall panels and collapses the front and rear wall panels after the top has been separated from the front and rear wall panels. After the rear wall panel has been collapsed, the front wall panel is collapsed then the side walls are collapsed. The container is now fully collapsed.

An alternative embodiment of collapsible container comprises a base, a top, side walls hinged to the base and top with living hinges. The side walls are integral with the top and base so as to form an integral ring or loop which results in enhanced strength and integrity of the container. Each of the side walls comprises upper and lower portions hinged together with a living hinge so as to enable each side wall to collapse inwardly.

The collapsible container further comprises front and rear walls hingedly secured to the base. The rear wall may have an upper portion and a lower portion, the lower portion being pivotally or hingedly secured to the base with a hinge. This lower portion may form an obtuse angle with the upper portion of the rear wall when the container is erected. A door may be hinged to one of the walls for access to the interior of the erected container. Alternatively, a door may be formed in one of the walls.

This embodiment further comprises flaps hinged to the side walls. At least some of these flaps, if not all, may be integral with the side walls. Others may be secured to the side walls with hinges. To erect the container and keep it in an erected condition, the flaps are secured to the front and rear walls of the container with fasteners or any other suitable securement. In one embodiment, three flaps are hinged to one edge of each side wall for securing the side wall to the rear wall and two flaps are hinged to an opposing edge of the side wall for securing the side wall to the front wall. At least one fastener is located on each of the flaps for such securement. Each fastener may comprise a rotatable latch adapted to pass through an opening in one of the front and rear walls. Of course, any other suitable fasteners may be used to secure the flaps to the collapsible front and rear walls.

In this embodiment, the top of the collapsible airline container may have two opposed flanges which may be bent downwardly from the generally planar main portion of the top. The flanges in one embodiment are integral with the main portion of the top but may be separate pieces hinged to the main portion or body of the top of the container. Fasteners may be used to secure these flanges to the front and rear walls of the container in aid in the erection of the container. The fasteners may assume numerous configurations or types and in one embodiment comprise rotatable latches adapted to pass through openings in the front and rear walls of the container before being rotated during erection of the container. Of course, any other suitable fasteners may be used to secure the top to the collapsible front and rear walls of the container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the container of the present invention in an erected condition;

FIG. 2 is a perspective view of the container of the present invention in a collapsed condition;

FIG. 3 is a perspective view of the collapsed container of FIG. 2 illustrating the side walls being erected;

FIG. 4 is a perspective view of the container of FIG. 3 illustrating the side walls fully erected;

FIG. 5 is a perspective view of the container of FIG. 4 illustrating the front and rear wall panels being erected;

FIG. 6 is a perspective view of the container of FIG. 5 illustrating the flaps being secured to the front wall panel of the erected container;

FIG. 7A is a perspective view of one of the rotatable latches used in accordance with the present invention in an unlocked position;

FIG. 7B is a perspective view of the rotatable latch of FIG. 7A in a locked position;

FIG. 8 is a perspective view of the erected container of FIG. 1 illustrating the base of the container;

FIG. 9 is a rear elevational view taken along the line 9-9 of FIG. 2;

FIG. 10 is a perspective view of the erected container of FIG. 1 illustrating products being placed into the interior of the container;

FIG. 11 is a view taken along the line 11-11 of FIG. 8;

FIG. 12 is a perspective view of an alternative embodiment of container in an erected condition;

FIG. 13 is a perspective view of the container of FIG. 12 in a collapsed condition;

FIG. 14 is a perspective view of the collapsed container of FIG. 12 illustrating the side walls being erected;

FIG. 15 is a perspective view of the container of FIG. 12 illustrating the side walls but not the container fully erected;

FIG. 16 is a perspective view of the container of FIG. 12 illustrating the front and rear walls being erected;

FIG. 17 is a perspective view of the container of FIG. 12 illustrating the flaps being secured to the front wall;

FIG. 18 is a perspective view of the erected container of FIG. 12 illustrating the base of the container;

FIG. 19 is a rear elevational view taken along the line 19-19 of FIG. 13;

FIG. 20 is a perspective view of the erected container of FIG. 12 illustrating products being placed into the interior of the container;

FIG. 21A is a perspective view of one of the rotatable latches used in accordance with the present invention in an unlocked position; and

FIG. 21B is a perspective view of the rotatable latch of FIG. 21A in a locked position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings and particularly to FIG. 1, there is illustrated a collapsible container 10 movable between an erected condition or position illustrated in FIGS. 1 and 8 and a collapsed condition or position illustrated in FIGS. 2 and 9. The collapsible container 10 is designed for use inside an aircraft luggage hold but may be used in another environment or for any other purpose.

As best illustrated in FIG. 8, the collapsible container 10 comprises a generally rectangular and generally planar base 12 having an upwardly directed flange 13 around the periphery thereof. The base 12 is preferably made of one piece of plastic material. However, other materials or other configurations may be used without departing from the present invention.

As shown in FIG. 1, a pair of side walls 14 are hingedly secured to the base 12 and more particularly to upwardly directed flanges 13 located around the periphery of the base 12 with horizontally oriented hinges 16 shown in FIG. 9. Each hinge 16 is preferably a co-extruded plastic hinge made by the Bradford Company of Holland, Mich. but may be any other type of hinge.

Each side wall 14 comprises a lower wall panel 18 hingedly secured to an upper wall panel 20 with a horizontally oriented hinge 22. Each hinge 22 is preferably a co-extruded plastic hinge like hinges 16, but may be any other type of hinge. Each wall panel 18, 20 is preferably made of one piece of plastic material, but may be multiple pieces or made with any other suitable material. Although the wall panels 18, 20 of each side wall 14 are preferably made of the same material, they may be different materials.

As shown in FIGS. 3 and 9, hinges 22 enable each side wall 14 to fold or collapse inwardly so that the upper wall panel 20 overlays or lays on top of the lower wall panel 18 when the container 10 is collapsed. As shown in FIG. 9, each hinge 22, as well as each hinge 16, comprises a pair of U-shaped receptacles 23 and a flexible joining member 25 joining the receptacles 23 and enabling them to move relative to one another.

As shown in the figures, at least one of the side walls 14 has a collapsible door 24 adapted to cover an opening 26 formed in the side wall. See FIG. 10. The door 24 is hingedly joined to the side wall 14 with a vertically oriented hinge 28 and movable between a closed position as shown in FIG. 1 and an open position as shown in FIG. 10. The door 24 has an upper portion or section 30 and a lower portion or section 32 separated by hinge 22. In the illustrated embodiment, each section 30, 32 comprises one piece of plastic; however, other materials of any desired size may be used for the door sections.

Each section 30, 32 of door 24 may be latched or locked in a closed position with a latch 34 a, 34 b, respectively. As seen in FIG. 6, a portion of each latch 34 a, 34 b is located on the door section 30, 32 and another portion of the latch 34 a, 34 b is located on one of the side wall panels 20, 18. See FIG. 10. In one embodiment, each latch 34 a, 34 b is manufactured by McMaster-Carr of Aurora, Ohio. Latch 34 a is sold as Part No. 10425 A86 and latch 34 b is sold as Part No. 10425 A84. See www.mcmaster.com. Either of the latches may be locked if desired. However, latches 34 a, 34 b may be any other suitable latching or locking members.

FIG. 11 illustrates hinge 28 in further detail. In one embodiment, hinge 28 is a 270 degree hinge extrusion manufactured by Filtrona Extrusion of Athol, Mass. and sold as Part No. 1440. See www.filtrona.com. However, hinge 28 may be any other suitable hinge. Hinge 28 comprises a pair of generally U-shaped receptacles 29, retaining lower wall panel 18 and the lower section 32 of the door 24, respectively in any desired manner. The hinge 28 further comprises a joining member 31 which enables movement of the receptacles 29 and their contents relative to one another.

As best seen in FIG. 3, flaps 36 a, 36 b and 36 c are hingedly secured to side edges 38 a, 38 b and 38 c, respectively, of each side wall 14. More particularly, upper flaps 36 a are hingedly secured to side edges 38 a of upper wall panels 20 with hinges 40 a. Similarly, middle flaps 36 b are hingedly secured to side edges 38 b of lower wall panels 18 with hinges 40 b. Lastly, lower flaps 36 c are hingedly secured to side edges 38 c of lower wall panels 18 with hinges 40 c.

As seen in FIGS. 3 and 4, on the other end of each side wall 14, flaps 36 d and 36 e are hingedly secured to side edges 38 d and 38 e, respectively, of each side wall 14. More particularly, flaps 36 d are hingedly secured to side edges 38 d of upper wall panels 20 with hinges 40 d. Similarly, flaps 36 b are hingedly secured to side edges 38 e of lower wall panels 18 with hinges 40 e.

Preferably, each flap 36 a-36 e is a single piece of plastic material. However, any of the flaps may be made of any number of pieces of any suitable material and of any desired size.

In one embodiment, hinges 40 a-40 e, all used to secure flaps to side wall panels 18, 20, are 270 degree hinge extrusions like hinge 28 used on the door 24, shown in detail in FIG. 11 and manufactured by Filtrona Extrusion of Athol, Mass. and sold as Part No. 1440. See www.filtrona.com. However, these hinge may be any other suitable hinges.

As shown in FIG. 6, the collapsible container 10 further comprises a front wall panel 42 hingedly joined to base 12 with horizontally oriented hinge 44. Hinge 44 in the embodiment shown is the same hinge as hinges 16 and 22 shown in detail in FIG. 9 and described above. As best shown in FIGS. 3 and 4, front wall panel 42 has at least one hole or opening 46 therethrough at the end of the front wall panel 42 opposite where it is joined to base 12 with hinge 44. This end becomes the top of the front wall panel 42 when the container 10 is erected. Similar holes or openings 48 through the front wall panel 42 are located along the sides of the front wall panel 42. As shown in FIG. 6, a nylon strap 50 is secured at its upper end 52 to the outside surface 54 of the front wall panel 42 and used for raising the front wall panel 42 from a horizontal collapsed position shown in FIGS. 3 and 4 to an erected or raised position shown in FIG. 6.

As best shown in FIGS. 1 and 8, the collapsible container 10 further comprises a rear wall panel 56 hingedly joined to base 12 with horizontally oriented hinge 58. Hinge 58 in the embodiment shown is the same hinge as hinges 16 and 22 shown in detail in FIG. 9 and described above. (also the same as hinge 44 shown in FIG. 6). As best shown in FIG. 5, rear wall panel 56 has a living hinge, crease or fold 60 separating the rear wall panel 56 into an upper portion or section 62 and a lower portion or section 64. As best illustrated in FIG. 8, when the container 10 is erected, the upper portion 62 is vertically oriented and forms an obtuse angle 66 with the lower portion 64. As best illustrated in FIG. 5, when the container 10 is collapsed, the upper portion 62 lays on top of the lower portion 64.

Like the front wall panel 42, the rear wall panel 56 has at least one hole or opening 68 therethrough at the end of the rear wall panel 56 opposite where it is joined to hinge 58. This end becomes the top of the rear wall panel 56 when the container 10 is erected. Similar holes or openings 70 through the rear wall panel 56 are located along the sides of the rear wall panel 56 to aid in erecting the container 10. See FIG. 5. As shown in FIG. 5, a nylon strap 72 is secured at one end 74 to the outside surface 76 of the rear wall panel 56 and used for raising the rear wall panel 56 from a horizontal collapsed position shown in FIGS. 3 and 4 to an erected or raised position shown in FIGS. 1 and 8. As shown in FIG. 5, when the rear wall panel 56 is collapsed, an inner surface 78 of the upper portion 62 of the rear wall panel 56 is upwardly directed while an inner surface 78 a of the lower portion 64 of the rear wall panel 56 is downwardly directed.

It is within the contemplation of the present invention that other devices other than nylon straps 50, 72 may be used to raise the front and rear wall panels 42, 56, respectively.

The collapsible container 10 further comprises a top or top panel 80 hingedly joined to the upper wall panels 20 of the side walls 14 with horizontally oriented hinges 82. Hinge 82 in the embodiment shown is the same hinge as hinges 16 and 22 shown in detail in FIG. 9, hinge 44 shown in FIG. 6 and hinge 58 shown in FIG. 8, described above. Any other suitable hinge may be used if desired. As best shown in FIGS. 3 and 4, top 80 has a pair of flanges 84 extending downwardly from a main portion 85 of the top 80.

As shown in FIG. 7A, at least one fastener in the form of a rotatable latch 86 is secured to each flange 84 of the top 80. The rotatable latch 86 may be riveted or secured in any suitable manner to an inside surface 88 of flange 84. The rotatable latch 86 comprises a stationary portion 90 and a rotatable portion 92. See FIGS. 7A and 7B. One fastener or rotatable latch which has proven satisfactory is manufactured by Friedola Tech Holzapfel Gmbh of Germany and sold as Part No. M931020. However, any other suitable latch or fastener may be used.

Referring to FIG. 5, in order to secure the rear wall panel 56 to the flange 84 of the top 80, the rotatable portion 92 of the latch 86 is passed through opening 68 in the rear wall panel 56 in its position shown in FIG. 7A and then rotated to a locked position shown in FIG. 7B.

As shown in FIG. 5, at least one fastener in the form of a rotatable latch 86 is secured to an inside surface of each flap 36 a-36 e and adapted to pass through holes 70 in the rear wall panel 56. Similarly, at least one fastener in the form of a rotatable latch 86 is secured to an inside surface of each flap 36 d and 36 e and adapted to pass through holes 48 in the front wall panel 42.

Referring to FIG. 3, the method of assembling the collapsible container 10 will now be described. Beginning with the collapsed container 10 shown in FIG. 2, two operators or assemblers 94 a and 94 b are provided. Simultaneously, they lift the top 80 or upper portions 20 of the side walls 14 up as shown in FIG. 3, thereby erecting the side walls 14 of the container 10 including the door 24. At this point, the front and rear wall panels 42, 56 of the container 10 are still in their collapsed condition or position. See FIGS. 3 and 4. FIG. 4 shows the container with the side walls 14 fully erect and the flaps 36 a-36 e located outside the side walls 14 of the container.

As shown in FIG. 5, assemblers 94 a and 94 b grab straps 72, 50, respectively and pull them upwardly to raise or pivot upwardly rear wall panel 56 and front wall panel 42, respectively. Front wall panel 42 is raised first by operator 94 b since it lays on top of rear wall panel 56 when the front and rear wall panels 42, 56 are collapsed above base 12.

As shown in FIG. 6, after the front and rear wall panels 42, 56 are erected or raised, one of the assemblers 94 a opens the door 24 and enters the interior of the partially erected container 10. The other assembler 94 b stays outside the container 10. The assembler 94 a passes the rotatable portions 92 of rotatable latches 96 secured to flanges 84 of top 80 through openings 46, 68 in the front and rear wall panels 42, 56, respectively. See FIG. 7A. The assembler 94 a inside the container 10 then rotates the rotatable portions of latches 96 as shown in FIG. 7B to secure the top 80 of the container to the front and rear wall panels 42, 56 of the container. Additionally, the assembler 94 a passes the rotatable portions 92 of rotatable latches 96 secured to flaps 36 a-36 e through openings 48,70 in the front and rear wall panels 42, 56, respectively. See FIG. 7A. The assembler 94 a inside the container 10 then rotates the rotatable portions of latches 96 as shown in FIG. 7B to secure the flaps 36 a-36 e of the container 10 to the front and rear wall panels 42, 56 of the container 10, the flaps 36 a-36 e being outside the front and rear wall panels 42, 56 of the container 10.

After the container 10 is fully assembled, the door may be closed and locked, if necessary, after products or items 96 are loaded inside the interior 98 of the container 10. See FIG. 10.

FIGS. 12-19 illustrate another embodiment of collapsible container 110 movable between an erected condition or position illustrated in FIGS. 12, 18 and 20 and a collapsed condition or position illustrated in FIGS. 13 and 19. The collapsible container 110 is designed for use inside an aircraft luggage hold but may be used in another environment or for any other purpose.

As best illustrated in FIGS. 12 and 18, the collapsible container 110 comprises a base 112, a pair of collapsible side walls 114 and a top 180 which are integrally joined together by living hinges or folds in a continuous but yet collapsible loop or ring of material 181. This collapsible ring 181 of the container 110 may be made of numerous pieces of material welded or otherwise joined together. In one embodiment, the collapsible ring 181 of the container 110 comprises multiple pieces of plastic material butt-welded together.

The base 112 has a pair of upwardly directed flange portions 113 on opposed sides of the base 112 which may remain vertically oriented when the container 110 is collapsed. See FIG. 19. These flange portions 113 are integrally joined by living hinges 116 to side walls 114. See. FIGS. 13 and 19. These living hinges 116 enable the collapsible side walls 114 to collapse inwardly on top of the base 112 as shown in FIGS. 13 and 19. Similarly, the side walls 114 and top 180 are integrally joined by living hinges 182 which enable the top 180 to collapse on top of the collapsed side walls 114 as shown in FIGS. 13 and 19.

As illustrated in FIG. 14, each side wall 114 comprises a lower wall portion 118 hinged to an upper wall portion 120 with a horizontally oriented living hinge 122 such that the upper and lower wall portions 120, 118 of each side wall 114 are integral with each other. Such configuration of side walls 114 enables each side wall 114 to collapse inwardly in a manner best illustrates in FIG. 14 so that the upper wall portion 120 overlays the lower wall portion 118 of each side wall 114 when the container 110 is collapsed.

As shown in FIGS. 12-19, at least one of the side walls 114 has a collapsible door 124 adapted to cover an opening 126 formed in the side wall. See FIG. 20. The door 124 is hingedly joined to the side wall 114 with a vertically oriented hinge 128 and movable between a closed position as shown in FIG. 12 and an open position as shown in FIG. 20. Hinge 128 may be identical to hinge 28 shown in FIG. 11 and described above. However, hinge 128 may be any other suitable hinge. Hinge 128 is shown in detail in FIG. 22 and comprises a pair of generally U-shaped receptacles 29 adapted to receive one of the side wall portions 118, 120 on one side and a portion of the door 124 on the other. The hinge 128 further comprises a joining member 131 which enables movement of the receptacles 129 and their contents relative to one another.

The door 124 has an upper portion or section 130 and a lower portion or section 132 separated by a living hinge 123. In this illustrated embodiment, the door 124 comprises one piece of plastic collapsible or foldable due to living hinge 123. Although one type of door is illustrated, other doors of any desired size or material may be used.

Each section 130, 132 of door 124 may be latched or locked in a closed position with a latch or lock 134 a, 134 b, respectively. As seen in FIG. 17, a portion of each latch 134 a, 134 b is located on the door section 130, 132 and another portion of the latch 134 a, 134 b is located on one of the side wall portions 120, 118. See FIG. 20. The latches or locks 134 a, 134 b may be identical to latches 34 a, 34 b described above or may be different.

As best seen in FIGS. 14 and 15, flaps 136 a and 136 b are integral with and hinged to upper and lower portions 120, 118, respectively, of each side wall 114 by living hinges 138 a, 138 b, respectively. More particularly, upper flaps 136 a are hinged to upper portions 120 of side walls 114 with living hinges 138 a. Similarly, middle flaps 136 b are hinged to lower portions 118 of side walls 114 with living hinges 138 b. Thus, flaps 136 a and 136 b are part of the side walls 114 and part of the loop or ring of material 181 described above.

Lastly, lower flaps 136 c are hingedly secured to side edges 138 c of lower wall portions 118 of side walls 114 with hinges 140. Each lower flap 136 c is a separate piece of material, preferably plastic. However, flaps 136 c may be made of any suitable material and of any desired size or configuration. Hinges 140, used to secure flaps 136 c to side walls 114 are 270 degree hinge extrusions like hinge 28 used on the door 24, shown in detail in FIG. 11 and described above. However, these hinges 140 may be any other suitable hinges.

As seen in FIGS. 14 and 15, on the other end of each side wall 114, flaps 136 d and 136 e are hinged to each side wall 114 and integral with each side wall 114. More particularly, flaps 136 d are hinged to upper wall portions 120 of side walls 114 with living hinges 138 d. Similarly, flaps 136 e are hinged to lower wall portions 118 of side walls 114 with living hinges 138 e. Thus, flaps 136 d and 136 e are part of the side walls 114 and part of the loop or ring of material 181 described above.

As shown in FIG. 17, the collapsible container 110 further comprises a front wall 142 hingedly joined to base 112 with horizontally oriented hinge 144. Hinge 144 in the embodiment shown is the same hinge as hinges 16 and 22 shown in detail in FIG. 9 and described above. As best shown in FIGS. 14 and 15, front wall 142 has at least one hole or opening 146 therethrough at the end of the front wall 142 opposite where it is joined to base 112 with hinge 144. This end becomes the top of the front wall 142 when the container 110 is erected. Similar holes or openings 148 through the front wall 142 are located along the sides of the front wall 142. As shown in FIG. 17, a nylon strap 150 is secured at its upper end 152 to the front wall 142 and used for raising the front wall 142 from a horizontal collapsed position shown in FIGS. 14 and 15 to an erected or raised position shown in FIG. 17. FIG. 17 shows the strap 150 hanging outside the outside surface 154 of the front wall 142.

As best shown in FIG. 18, the collapsible container 110 further comprises a rear wall 156 hingedly joined to base 112 with horizontally oriented hinge 158. Hinge 158 in the embodiment shown is the same hinge as hinges 16 and 22 shown in detail in FIG. 9 and described above. (also the same as hinge 44 shown in FIG. 6). As best shown in FIGS. 16 and 18, rear wall 156 has a living hinge, crease or fold 160 separating the rear wall 156 into an upper portion or section 162 and a lower portion or section 164. As best illustrated in FIG. 18, when the container 110 is erected, the upper portion 162 is vertically oriented and forms an obtuse angle 166 with the lower portion 164 of the rear wall 156. As best illustrated in FIG. 16, when the container 110 is collapsed, the upper portion 162 lays on top of the lower portion 164.

Like the front wall 142, the rear wall 156 has at least one hole or opening 168 therethrough at the end of the rear wall 156 opposite where it is joined to hinge 158. This end becomes the top of the rear wall 156 when the container 110 is erected. Similar holes or openings 170 through the rear wall 156 are located along the sides of the rear wall 156 to aid in erecting the container 110. See FIG. 16. As shown in FIG. 12, a nylon strap 172 is secured at one end 174 to the rear wall 156 and used for raising the rear wall 156 from a horizontal collapsed position shown in FIGS. 14 and 15 to an erected or raised position shown in FIGS. 12 and 18. As shown in FIGS. 16 and 17, when the rear wall 156 is collapsed, an inner surface 178 of the upper portion 162 of the rear wall 156 is upwardly directed while an inner surface 178 a of the lower portion 164 of the rear wall 156 is downwardly directed. Thus, when the rear wall 156 is collapsed, the upper portion 162 of the rear wall 156 is folded relative to of the lower portion 164 of the rear wall 156 and rests or resides on top of the lower portion 164 of the rear wall 156.

It is within the contemplation of the present invention that other devices other than flexible nylon straps 150, 172 may be used to raise and lower the front and rear walls 142, 156, respectively.

The collapsible container 110 further comprises a top 180 hinged to the upper wall portions 20 of the side walls 114 with horizontally oriented living hinges 182 such that the top 180 is integral with the side walls 114. As such the top 180 forms part of the loop or ring 181 of the container 110. As best shown in FIGS. 14 and 15, top 180 has a pair of flanges 184 extending downwardly from a main portion 185 of the top 180 and integral with the main portion 185 of the top 180 via living hinges 183. Although two flanges 184 are illustrated, any number of flanges of any desired size may be integral with the main portion 185 of the top 180 via living hinges. Alternatively, flaps (not shown) may be hinged to the top 180 to secure the top 180 to the front and rear walls when the container 110 is erected.

As shown in FIG. 21A, at least one fastener in the form of a rotatable latch 186 like the one shown in FIG. 7A is secured to each flange 184 of the top 180. The rotatable latch 186 may be riveted or secured in any suitable manner to an inside surface 188 of flange 184. The rotatable latch 186 comprises a stationary portion 190 and a rotatable portion 192. See FIGS. 21A and 22B. One fastener or rotatable latch which has proven satisfactory is manufactured by Friedola Tech Holzapfel Gmbh of Germany and sold as Part No. M931020. However, any other suitable latch or fastener may be used.

Referring to FIGS. 16, 21A and 21B, in order to secure the rear wall 156 to the flange 184 of the top 180, the rotatable portion 192 of the latch 186 is passed through opening 168 in the rear wall 156 in its position shown in FIG. 21A and then rotated to a locked position shown in FIG. 21B. The same procedure is used to secure the front wall 142 to the opposite flange 184 of the top 180. Although only one fastener is illustrated securing the front wall 142 to the top 180 and another one securing the rear wall 156 to the top 180 of the container 110, any number of fasteners may be used.

As shown in FIG. 16, at least one fastener in the form of a rotatable latch 186 is secured to an inside surface of each flap 136 a-136 c and adapted to pass through holes 170 in the rear wall 156. Similarly, at least one fastener in the form of a rotatable latch 186 is secured to an inside surface of each flap 136 d and 136 e and adapted to pass through holes 148 in the front wall 142. Any number of fasteners of any desired type or configuration may be used to secure any of the flaps 136 a-136 e to either the front wall 142 or rear wall 156 of the container 110.

Although not illustrated, it is within the contemplation of the present invention that any number of flaps be secured to or integral with the front and rear walls 142, 156 of the container 110 instead of being secured to or integral with the side walls 114 of the container 110, as illustrated and described. In either event, the flaps may be used to secure the front and rear walls 142, 156 of the container 110 to the collapsible side walls 114 of the container 110 when the container 110 is erected.

The container 110 is preferably made of plastic material. However, other materials or other configurations may be used without departing from the present invention. Although reference is made to made in this document to a front wall panel or front wall, a rear wall panel or rear wall and side walls, it will be appreciated that the collapsible container 10 or 110 may be oriented in any direction so that, for example, the front wall panel or front wall is actually at the rear of the erected container.

Referring to FIG. 14, the method of assembling the collapsible container 110 will now be described. Beginning with the collapsed container 110 shown in FIG. 13, two operators or assemblers 194 a and 194 b are provided. Simultaneously, they lift the top 180 and/or upper portions 120 of the collapsed side walls 114 up as shown in FIG. 14, thereby erecting the side walls 114 of the container 110 including the door 124. At this point, the front and rear walls 142, 156 of the container 110 are still in their collapsed condition or position. See FIGS. 14 and 15. FIG. 15 shows the container 110 with the side walls 114 fully erect and the flaps 136 a-136 e located outside the side walls 114 of the container 110.

As shown in FIG. 16, assemblers 194 a and 194 b grab straps 172, 150, respectively and pull them upwardly to raise or pivot upwardly rear wall 156 and front wall 142, respectively. Front wall 142 is raised first by operator 194 b since it lays on top of rear wall 156 when the front and rear wall 142, 156 are collapsed above base 112.

As shown in FIG. 17, after the front and rear walls 142, 156 are erected or raised, one of the assemblers 194 a opens the door 124 and enters the interior of the partially erected container 110. The other assembler 194 b stays outside the container 110. The assembler 194 a passes the rotatable portions 192 of rotatable latches 186 secured to flanges 184 of top 180 through openings 146, 168 in the front and rear walls 142, 156, respectively. See FIG. 21A. The assembler 194 a inside the container 110 then rotates the rotatable portions of latches 186 as shown in FIG. 21B to secure the top 180 of the container 110 to the front and rear walls 142, 156 of the container. Additionally, the assembler 194 a passes the rotatable portions 192 of rotatable latches 186 secured to flaps 136 a-136 e through openings 148, 170 in the front and rear walls 142, 156, respectively. See FIG. 21A. The assembler 194 a inside the container 110 then rotates the rotatable portions of latches 186 as shown in FIG. 21B to secure the flaps 136 a-136 e of the container 110 to the front and rear walls 142, 156 of the container 110, the flaps 136 a-136 e being outside the front and rear walls 142, 156 of the container 110.

After the container 110 is fully assembled, the door 124 may be closed and locked, if necessary, after products or items 96 are loaded inside the interior 198 of the container 110. See FIG. 20.

Although the figures illustrate a known method of assembling the collapsible containers of the present invention, any other suitable known method may be used to assembly a collapsed container built in accordance with the present invention.

While we have described several embodiments of our invention in detail, we do not intend to be limited except by the scope of the following claims. For example, wherever a living hinge is illustrated and described, alternatively a separate hinge may be used. Likewise, wherever a separate hinge is illustrated and described, a living hinge may be used. 

1. A collapsible container comprising: a base; a top having two opposed flanges; a front wall hingedly secured to said base; a rear wall hingedly secured to said base; side walls integral with said base and top, each of said side walls being collapsible inwardly; flaps hinged to said side walls, wherein said flaps and said flanges of said top may be secured to said front and rear wall panels to erect said container.
 2. The collapsible container of claim 1 wherein said front and rear walls each have a strap secured thereto to aid in assembly of said container.
 3. The collapsible container of claim 1 further comprising a collapsible door hinged to one of said walls.
 4. The collapsible container of claim 1 wherein said flaps and said flanges of said top may be secured to said front and rear walls with fasteners.
 5. The collapsible container of claim 1 wherein each of said side walls has an upper portion integral with a lower portion.
 6. The collapsible container of claim 1 wherein at least some of said flaps are integral with said side walls.
 7. The collapsible container of claim 1 wherein at least some of said flaps are secured to said side walls with hinges.
 8. A collapsible container comprising: a base; a top having two opposed flanges; a front wall secured to said base with a hinge; a rear wall having a upper portion and a lower portion, said lower portion being secured to said base with a hinge and forming an obtuse angle with said upper portion of said rear wall when said container is erected; side walls integral with said base and said top, each of said side walls having integral upper and lower portions hinged together so as to enable said side wall to hinge and collapse inwardly; flaps integral with said side walls for securing said side walls to said front and rear walls when said container is erected.
 9. The collapsible container of claim 8 wherein at least some of said flaps have fasteners attached thereto which may pass through openings in said front and rear walls for assembly of said container.
 10. The collapsible container of claim 8 further comprising a collapsible door.
 11. The collapsible container of claim 9 further comprising fasteners attached to said flaps for erecting the container.
 12. The collapsible container of claim 10 wherein said door has an upper portion integral with a lower portion.
 13. A collapsible container comprising: a base; a top; a front wall hingedly secured to said base; a rear wall hingedly secured to said base; side walls integral with said base and top, each of said side walls having integral upper and lower portions hinged together and being collapsible inwardly; flaps for securing said side walls to said front and rear walls to erect said container.
 14. The collapsible container of claim 13 wherein each of said flaps has latches thereon which pass through said front and rear walls and are used to assemble the container.
 15. The collapsible container of claim 13 wherein said top has opposed flanges, each of said flanges having latches thereon which pass through said front and rear walls and are used to assemble the container.
 16. The collapsible container of claim 13 further comprising hinges joining said front and rear walls to said base.
 17. The collapsible container of claim 13 further comprising a door having an upper portion hinged to a lower portion.
 18. A method of erecting a collapsible container, the method comprising the steps of: providing a collapsed container; lifting a top of the collapsed container, thereby erecting side walls of the collapsed container; lifting front and rear walls hingedly secured to a base of the collapsed container; securing the top of the container to the front and rear walls of the container; securing flaps hinged to said side walls of the container to the front and rear walls of the container.
 19. The method of claim 18 wherein securing the top of the container to the front and rear walls of the container comprises passing rotatable latches through openings in the front and rear walls of the container and rotating the latches to prevent the latches from passing through the openings in the front and rear walls of the container.
 20. The method of claim 18 wherein lifting said front and rear walls of the collapsed container comprises pulling on a strap secured to each of said front and rear walls.
 21. The method of claim 18 wherein said step of securing flaps hinged to said side walls of the container to the front and rear walls of the container comprises passing rotatable latches located on the flaps of the container through openings in the front and rear walls of the container and rotating the latches.
 22. A method of erecting a collapsible container, the method comprising the steps of: providing a collapsed container having a top with opposed flanges, each of said flanges having at least one latch thereon; raising the top of the collapsed container, thereby erecting collapsed side walls of the collapsed container, each of the side walls having flaps hinged thereto and at least one of the side walls having a collapsible door formed therein; lifting front and rear walls hingedly secured to a base of the collapsed container; passing said latches located on the flanges of the top of the container through openings in the front and rear walls of the container; securing the top of the container to the front and rear walls of the container with the latches; passing latches located on the flaps of the container through openings in the front and rear walls of the container; securing the flaps of the container to the front and rear walls of the container using the latches. 